cold spray materials manufacturing technology research · cold spray technology evolution powder...

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UNCLASSIFIED The Nation’s Premier Laboratory for Land ForcesApproved for Public Release; Distribution Unlimited

UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces

UNCLASSIFIED

Approved for Public Release; Distribution Unlimited

Cold Spray Materials Manufacturing

Technology Research

Blake Barnett

Materials Engineer, Advanced Materials & Processes Team

[email protected]

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• The Case for Cold Spray: Nonthermal Additive Manufacturing

• ARL Center for Cold Spray Research & Technology Background

• 1st Generation Cold Spray Repairs

• Beyond Nonstructural Repair

• Holistic Modeling Approach and Results

• Modeling-Enabled Performance and Applications

• Future AM Efforts and Capabilities

Outline

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Nonthermal Additive Consolidation

Traditional Process Additive Process

Casting, WeldingSLM, EBM, Wire-Arc Additive

Manufacturing (WAAM)

Sintering Powder Binder Jet, Single-Pass Jetting

Extrusion Fused Deposition Modeling

Forging Strain-Mediated Additive Manufacturing

Solid-State

Deformation

Processing

Retained & Refined

Microstructures for

Enhanced Net & Near-Net

Shape Materials

Architected

Feedstocks

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Cold Spray Overview

Modeling & Simulation

Powder Development

Cold Spray Materials

Characterization

Advanced Processing

Applications Development

Equipment (VRC Gen III-JOA)

Specifications, Stds. & Training

Transition & Implementation

ARL is Recognized as International Leader in Cold Spray Technology

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Cold Spray Technology Evolution

POWDER SYNTHESIS MODELING & SIMULATION

PRODUCTION SCALE-UP

PROCESS DEVELOPMENT

TRL 9

TRL 8

TRL 7

TRL 6

TRL 5

TRL 4

TRL 3

TRL 2

TRL 1

CHARACTERIZATION & TESTING

UH-60 Sump Repair

RDECOM TMR

OSD & Army Mantech

NAVAIR

AFRL

Navy-TIPS

ESTCP

DLA

SBIR

SERDP

ARL,ONR

IndustryAF & Army RIF

MEO B1671

Near Net Shape Spray Form Components

Flexible Robot EnvironmentFirst Approved Army-Navy & Air Force Applications

TD-63 Actuator

PowderFEB Panels & Hydro

B-1

0

20

40

60

UTS,ksi

YS,ksi

%EL

annealed

T4-T451

T6-T651

coldsprayed

UTS = to wrought

VISION: Non-structural Repair Structural Repair Near-net Parts

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Cold Spray Background

Main Gas Stagnation Pressure 0.5-5 MPa

Gas Temperature 0-1000ºC

Main Gas Flow Rate 30-200 m3/hr

Powder Feed Rate 1 to 15 kg/hr

Particle Velocity 300-1500 m/sec.

Particle Size 1-50um diameter

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Cold Spray Demonstration

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1. Maintenance Engineering Order (MEO) T7631 UH-60 Sump Repair

• Army Aviation & Missile Research, Development & Engineering Center (AMRDEC)

•Program Office –UH-60 Blackhawk

•Corpus Christi Army Depot-SAFR Program Office

2. Overhaul Repair Instruction (ORI) SS8491 UH-60 Sump Repair

•Sikorsky Aircraft Company-Technology Integration

UH-60 Sump - Magnesium Housing

ROI for the UH-60 Sump

Unit Cost: $11K

Annual Demand Rate: 85

Repair Cost: $880

Investment: $60K

Annual Savings $860K

Before After

UH-60 Sump UH-60 SumpCorrosion Sites

Official Approval Documents and Commitment

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Post-Processing

• Machining

• Heat treating

• Forming

• Surface treating

9

Cold Spray Process

ParticleImpact

• Deformation

• Heat generation

• Recrystallization

ProcessParameters

• Gas temperature

• Gas pressure

• Gas composition

• Particle feeder temp.

• Laser assistance

Process Parameters

ParticleImpact

Bulk Material

User-input

Parameters

Prediction of Properties

PowderProduction

• Microchemistry

• Microstructure

• Process parameters

• Particle & grain size

PowderProcessing

• Degassing

• Heat treating

• Milling

• Blending

PowderProduction

PowderProcessing

Holistic Approach to Cold Spray AM Integrated Computational Materials Engineering (ICME)

Predictive

models to

complement

experimental

approach

Process Model for Materials Development

Output from Powder Production & Powder Pre-Processing

models are used as input to the Particle Impact Model

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Alloy Parameters Specimen ID HRB %IACSUTS MPa

(ksi)%El

Press. Temp

6061 20 bar 400°C CS-12-275 31.0 44.03 239 (34.6) 7

6061 25 bar 450°C CS-13-096 40.4 41.5 310 (45.0) 5

2024 25 bar 400°C CS-14-150 64.6 30.18 392 (56.8) 5.8

2024 30 bar 500°C CS-14-152 57.3 31.96 346 (50.2) 10.9

7075 25 bar 400°C CS-14-128 65.2 31.08 387 (56.2) 6.9

7075 25 bar 400°C CS-14-120 50.1 35.92 326 (47.3) 11.8

7075 30 bar 500°C CS-14-125 62.7 31.11 394 (57.2) 11.5

5056 20 bar 500°C CS-14-101 63 26.25 406 (58.9) 15.4

Technical Results-CS Al Alloys

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Fielded Applications of Cold Spray

•Power Transfer Module - PTM- 10 Magnesium Castings

•Transmission- 13 Magnesium Castings

Three Fielded Blackhawk Medvac Units with Cold Spray Al Repair Operating Since August, 2009ARL/AMCOM/Ft. Hood Collaboration

Fielded SH-60 Seahawk with Cold Spray Mg Repair Operating Since August, 2009-Australian Navy

ARL/JSF/DSTO Collaboration

Two Expeditionary Fighting Vehicles with Cold Spray Mg Repair Fielded and Operating Since September, 2008

Fielded B-1 Bomber with Cold Spray Ti Repair Operating Since September 2009- Tinker AFB

ARL/Tinker AFB/HF Webster Collaboration

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Fielded Applications (Cont’d)

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Approved Cold Spray Repair Processes

ARMYAH-64 Intermediate Gear Support ( EYAB: 12-153 top & outer land repair)UH-60 Sump (MEO T7631B MEO B1671 packing seal surface repair)MEO-B1718 T-700 Turbine Engine Front Frame –FY15UH-60 Intermediate Gearbox (MEO B1089 center, input, output housings)

UH-60 Tail Rotor Gearbox (MEO B1090 center, input, output housings)UH-60 Accessory Gearbox (MEO B1091 cover and housing)UH-60 Input Module (MEO B1092 center, input, output housings)

NAVYF/A-18E/F AMAD Main Housing (hydraulic pad restoration)F/A-18E/F AMAD Main Housing (gear failure repair)

F/A-18E/F AMAD Hydraulic Gear Shaft seal surface repair)H-1 Mixer Gearbox (external chafing repair)

AIR FORCE

B-1 Forward Equipment Bay (FEB) Panels (ETAR) E12-00248B-1 Hydraulic Tube Repair (ETAR) E09-00065

MOOG has been

approved by

Boeing, Sikorsky

and Bell

Helicopters as a

Qualified Cold

Spray Vendor

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Cold Spray Additive Manufacturing

Axisymmetric Near-Net Shape Components

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Questions?

ARL Installation Spring 2018